Download Hyper 66DH/DHD360

HYPER 66DH
MAINTENANCE, OPERATING
AND SERVICE MANUAL
DHD360
Geothermal Water Well
Go drill it.
CONTENTS
Introduction
Components
Parts List
Specification
Air Consumption
Stripping the Hyper 66DH
Checking for wear & damage
Rebuilding the hammer
Button Bit footvalve
Lubrication
Storage Procedure
Troubleshooting
APPENDICES
Chuck Release Washers
Clamp Positions
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6-7
Section 8-9
Section 10
Section 11
Section 12
Section 13
Section 14
A
B
INTRODUCTION
1
The Bulroc Hyper 66DH is a strong, robust valveless DTH hammer of a simple and straightforward design to
provide maximum performance with a minimum of maintenance.
The Hyper 66DH is specifically designed to operate efficiently at air pressures between 10bar (150psi) and 30 bar
(430psi) and to operate efficiently at depths, overcoming high heads of water. The combined control tube, diverter
and check valve minimises the number of component parts, reducing the overall length of the hammer for ease
of handling.
The Hyper 66DH is supplied as standard with a check valve arrangement that is designed to help maintain
pressure inside the hammer when the air is turned off for rod changing and so prevent contaminated water from
entering the hammer. The standard backhead connection on the Hyper 66DH is 3�⁄�” API reg pin.
The Hyper 66DH hammer is designed to give optimum performance with minimum air consumption and is fitted
as standard with a Solid Air Choke. However, for particularly deep holes or excessively high inflows of water, a
selection of chokes are supplied with each hammer.
The Choke Plug can be completely removed if necessary giving a through hole size of 1/4” / 6.3mm.
Geothermal Water Well
WARNING
ALWAYS THINK
SAFETY FIRST!
This manual is published by and copyright © of Bulroc (UK) Ltd. All Rights Reserved. Always operate your Bulroc
drilling equipment according to the instructions contained within this operating manual. Further copies of this manual
can be downloaded from the Bulroc website; www.bulroc.com. For urgent support or sales enquiries, call Bulroc
on +44 (0)1246 544700 or Skype BULROCUKSALES . E & O.E
2 COMPONENTS
Backhead
Breakout
Washer
Compression
Buffer
Backhead
“O” Ring
Wearsleeve
Check
Valve
Check Valve
Spring
Control
Tube
Piston Retaining
Ring
Solid
Choke
Bush
Bush “O”
Rings
Bit Retaining
“O” Ring
Bit Retaining
Ring
Piston
Breakout
Washer
Chuck
3
PARTS LIST
1
3
14
2
4
7
5
6
15
Ref Description
Part Number
Qty
1
Backhead
HSH66DH3803M
1
2
Backhead ‘O’ Ring
HSH6114
1
3
Check Valve
IPRCV04
1
4
Check Valve Spring
IPRCVS04
1
5
Control Tube
HSH66DH30
1
6
Choke Set & allan key
HSH66DH19
1
7
Compression Buffer
HSH66DH22
1
8
Bush
HSH66DH86
1
9
Bush “O” Ring
HSH66DH87
1
10
Piston
HSH66DH03
1
11
Piston Retaining Ring
HSH6132
1
12
Bit Retaining Ring
HSH66DH37093
1
13
Chuck
HSH66DH35093
1
14
Breakout Washer
HSH66DH26
1
15
Wearsleeve
HSH66DH0093
1
16
Bit Retaining ‘O’ Ring
HSH66DH37A093
QUICK ORDER CODES
Complete Hammer
10
11
8
9
16
12
13
14
BR66DH01
SPECIFICATIONS
4
Overall length 40.90” (1039mm)
Hammer
Diameter 5.5”
(141 mm)
Imperial
Metric
Weight (less bit)
219 lbs
100 Kgs
Length (less bit)
43.03’’
1093 mm
Outside dia.
5.620’’
142.75 mm
Piston weight
Stroke
43.5 lbs
20 Kg
4.25’’
108 mm
AIR CONSUMPTION
5
Solid Choke Plug fitted as
standard
Additional Flushing
A solid choke is fitted at the end of the control tube. In certain drilling conditions, extra flushing air may
be required to overcome increased back pressure and to maintain sufficient up hole velocity to ensure
efficient hole cleaning.
In such conditions, the solid choke plug can be replaced with an open hole choke of a particular size or
can be removed completely to give the maximum amount of additional live flushing air, depending on
the operating pressure.
The top two tables show the extra flushing air that can be passed through each choke at different
pressures. The bottom two tables show the total air required for the Hyper 66DH hammer with different
chokes and at different operating pressures.
Extra flushing air for a choke in cubic feet per min
Extra flushing air for a choke in cubic metres per min
Hole Size
150 psi
200 psi
250 psi
300 psi
350 psi
400 psi
430 psi
Hole Size
0.063”
9.5
12.4
15.2
18.1
21
23.8
25.5
1.60 mm
10.3 bar 13.8 bar 17.2 bar 20.7 bar 24.1 bar 27.6 bar 29.7 bar
0.27
0.35
0.43
0.51
0.59
0.67
0.72
0.125”
37.5
49
60.3
71.8
83.2
94.5
101.3
3.20 mm
1.06
1.39
1.71
2.03
2.36
2.68
2.67
0.188
75
98
120.6
143.6
166.2
189
202.6
4.75 mm
2.12
2.78
3.42
4.07
4.71
5.35
5.74
0.250”
150
196
241.2
287.2
332.8
378
405.2
6.30 mm
4.25
5.55
6.83
8.13
9.42
10.7
11.47
Total air requirements for a choke in cubic feet per min
Total air requirements for a choke in cubic metres per min
Choke Size
150 psi
200 psi
250 psi
300 psi
350 psi
400 psi
430 psi
Choke Size
150 psi
200 psi
250 psi
300 psi
350 psi
400 psi
430 psi
blank
296.3
456.2
637.5
838
1056
1290.2
1439.8
blank
8.39
12.92
18.05
23.74
29.9
36.53
40.77
0.063”
305.8
468.6
652.7
856.1
1077
1314
1465.3
1.60 mm
8.66
13.27
18.48
24.24
30.5
37.21
41.49
1541.1
3.20 mm
9.45
14.31
19.76
25.76
32.26
39.21
43.64
1642.4
4.75 mm
10.51
15.69
21.47
27.8
34.61
41.89
46.51
6.30 mm
12.64
18.47
24.88
31.86
39.33
47.24
52.24
0.125”
0.188”
0.250”
333.8
371.3
446.3
505.2
554.2
652.2
697.8
758.1
878.7
909.8
981.6
1125.2
1139.2
1222.2
1388.8
1384.7
1479.2
1668.2
1845
STRIPPING THE HAMMER
6
After extensive drilling, the chuck and the back head
might become too difficult to loosen on a Hammer Bench
Splitter or the drill rig. In such conditions the breakout
washer can be ground or drilled which will relieve the
pressure and enable the chuck to be removed.
(NB. On no account should the wearsleeve be
impacted by a hammer. Splitting should never be
assisted by the use of localised heat, ie. Blow torch.
Any signs of hammer indentations or applied heat
will void the warranty.)
Breakout washer
Assuming now both the backhead and chuck threads
have been loosened either on the drill rig or a Hammer
Splitter, the stripping operation is as follows.
1.Remove the chuck assembly.
Breakout washer
Chuck
2.Removing the ‘O’ ring from the bit retaining ring
will allow the bit to be removed. Alternatively pulling
the two pieces apart will allow the ‘O’ ring to stretch
enough to fit over the end of the bit shank.
Bit retaining ring
+ “O” RIng
Bit
3.The bit can now be removed from
the chuck quite easily.
7
STRIPPING THE HAMMER
4.With the hammer laid horizontal, unscrew the
backhead and remove it from the wearsleeve.
5.The control tube assembly can now
be removed from the backhead
6.The checkvalve spring can now
be removed should it be necessary,
although generally this will not be
needed.
Guide bush
7.The guide bush can be removed by
tilting the wearsleeve downwards and
shaking. If this proved difficult , the
guide bush can be pushed out.
8.Tilting the hammer upside will allow the
piston to be removed, taking care to catch
the piston as it falls out.
9.Unless there is damage to the piston
retaining ring, there should be no need
to remove it. However if this should need
replacing , dropping an inverted piston down
the upright wearsleeve from the backhead
end should remove it.
Piston retaining
ring
8 CHECKING FOR WEAR & DAMAGE
Premature wear to internal parts is a result of either:1. Insufficient or incorrect lubrication.
2. The ingress of debris into the hammer.
3. Incorrect service and storage.
The maximum wear allowance shown in this section are a guide as to when to replace parts. In certain
conditions parts may need to be replaced before they reach the sizes shown.
Piston
Footvalve bore diameter
Control tube bore diameter
Body Diameter
Max Footvalve bore
Max Control tube bore
Min Body diameter
1.525”
1.610”
4.577”
38.73mm
40.89mm
116.26mm
There are two main areas to examine on a used piston:1. Check the body diameter for signs of pickup and burning (both are signs of poor lubrication). Using
a micrometer, measure the diameter and refer to the quoted minimum size above.
Any light ‘Pick up’ marks can be removed using emery cloth, however if there are signs of
overheating and cracking, the piston should be replaced and the lubrication system examined.
2. Secondly, using a micrometer, measure the diameter of the bore at both ends of the piston and refer
to the maximum quoted sizes.
3. Examine the striking face. Some degree of distortion is acceptable proving there are no signs of
cracking. If distortion has affected the chamfer and possibly distorted the footvalve bore diameter, this
needs to be reformed on a lathe and footvalve bore re-ground to its original diameter.Burrs and dents
can be removed with an emery stone.
CHECKING FOR WEAR & DAMAGE
8
Maintaining the piston face
Fig. 2 Worn Piston Face
Fig.1 New Piston Face
RADIUS “A”
CHAMFER “B”
During the working life of the hammer the Striking Face
on the Piston may become dented or deformed (see
fig.2). To prevent this face from cracking, or chipping,
the Piston should be returned to a lathe where the
strking face can be re-machined flat and then have
the outer radius and inner chamfer reformed (see fig.3)..
Care should be taken to remove the minimum amout of
material during this re-machining process and at no
point should more than 2mm be removed from the face.
Pistons with wear patterns, or indentations deeper
than 2mm should be replaced.
The table below contains useful machine information for
reforming the piston face.
MACHINE DETAIL
HAMMER
HYPER 66DH
Fig. 3 Area to be machined
RADIUS “A”
0.250”
CHAMFER “B”
0.125” @45
9 CHECKING FOR WEAR & DAMAGE
Control Tube
Note - Control Tube minimum
diameter 1.595” (40.51mm)
Diameter
Examine the control tube diameter using a micrometer. Check the diameter has
not worn under the specified minimum. If there are signs of pickup they should be
removed by using emery cloth.
Wearsleeve
Using either a micrometer or vernier,
measure the outer diameter of the
Wearsleeve. If it is below the minimum
it must be replaced. The wear rate of the
Wearsleeve can be slowed by replacing
the Chuck before the wear area reaches
the Wearsleeve.
The bore of the Wearsleeve should be
periodically checked for any signs of
‘Pick up’. If a piston has broken within
the wearsleeve it is imperative that the
bore is honed to remove any burrs or
‘pick-up’.
Failure to do so will result in ‘pick-up’ on
the replaced piston and will lead to early
failure of this component.
Diameter
Note - Wearsleeve minimum
diameter 5.25” (133.35mm)
REBUILDING THE HAMMER
10
1. Ensure all the maintenance work outlined in the previous section
has been completed.
1
2. Stand the wearsleeve(15) on the floor, with the Chuck end upwards.
Insert the piston retaining ring(11) into the bore and hammer the ring
down until it springs into the groove in the Wearsleeve.
3
14
2
4
7
5
3. Clamp the wearsleeve horizontally in a vice, taking care not to over
tighten the jaws. First fit the bit bush (8) with new “O” rings then push
into the wearsleeve. Assemble the chuck(13), breakout
washer(14) and bit retaining rings(12) (ensure to fit a new ‘O’ ring)
around the button bit. Cover the threads with a copper based grease.
Hand tighten the chuck assembly into the wearsleeve.
4. Coat the Piston(10) with Rock Drill oil and slide it into the
Backhead(1) end of the Wearsleeve. Ensure the Piston striking face
enters first.
5. Slide the Control Tube into the Wearsleeve.
6. Insert the Spring(4) into the Check Valve(3) and then slide the
assembly into the Control Tube.
6
15
7. Cover the threads of the backhead with a copper based grease
and insert it into the backhead end of the wearsleeve(15) by hand
tightening.
8. Should the backhead be removed, the wearsleeve should not be
inverted past the horizontal position, unless it is necessary to remove
the piston.
10
11
8
9
16
12
13
14
Note: Ensure both the backhead and chuck are fully torqued up
prior to commencing drilling.
11 BUTTON BIT FOOT VALVE
Foot Valve Diameter
38.1 mm / 1.500”
Protrusion Height
49.27 mm / 1.940”
The Bulroc Hyper 66 DHD 360 hammer is designed to be used with foot valves.
The correct foot valve must be fitted otherwise the performance of the hammer will be
seriously affected.
Using a foot valve which is larger in diameter than the specified will result in the rapid failure of
the foot valve.
Using a foot valve which is smaller in diameter than the size specified will greatly reduce the
performance of the hammer.
The protrusion height is also important and to ensure the correct height and prevent damage
when replacing the foot valve, it is recommended the correct insertion tool is used:
Bulroc Part Ref: BBFVIT093
12
LUBRICATION
The Hyper 66DH piston oscillates at 930 bpm at 150 psi (10bar). It is therefore extremely important
that an adequate supply of the correct type of rock drill oil is constantly fed to the hammer whilst it is
operating.
Failure to do so will quickly lead to excessive component wear and if the oil supply is cut off for any
reason, the piston will quickly seize inside the wearsleeve, resulting in irrepairable damage to both
components.
An air line lubrication system should be installed, preferably on the drill rig. The lubricator reservoir
should be of sufficient capacity to supply the required volume of rock drill oil for a full shift. It is
equally important that the lubricator system must be adjustable and have a visual check to ensure the
lubricator does not run out of oil.
As a good general guide, all Bulroc hammers require a third of a pint of oil per 100 cfm of air through the
hammer (0.07 litre per meter cubed).
Eg : Hyper 66DH operating at 150 psi = 296 cfm = 1 pint per hour.
10.3 bar = 8.4 M3 = 0.56 litre per hour.
The amount of lubrication oil should be increased by 50% when drilling with water or foam. When new
drill pipes are added to the drill string, it is recommended that a half pint (quarter of a litre) of rock drill
oil is poured into the pipe to provide a good internal coating and helps prevent the hammer from running
dry at any time. The grade of rock drill oil will be determined by the ambient temperature at the drilling
site. If the ambient temperature is between 0 and 25 degrees centigrade, then a 30 grade oil should be
used. If the ambient temperature is greater than 250 degrees centigrade, then use a 50 grade oil. Bulroc
supply their own recommended rock drill oil. See below for all the recommended brands of oils.
MAKE
TYPE 30 GRADE
TYPE 50 GRADE
BULROC
BP
CHEVRON
SHELL
ESSO/EXXON
T220
ENERGOL RD-E 100
ARIES 100
TORCULA 100
AROX EP100
T320
ENERGOL RD-E 300
ARIES 320
TORCULA 320
AROX EP320
13 STORAGE PROCEDURES
We recommend following the points listed below when removing a ‘Down the Hole’ hammer from service.
This will ensure trouble free operation once the hammer starts work again.
The hammer should be stripped and cleaned and freed of as much water/moisture as possible. Bulroc
320 or similar rock drill oil should be poured into the backhead, allowing all parts to be coated throughout
the hammer. The check valve should be depressed to help the ingress of oil.
Amount required ¾ of a pint or 0.43 litre.
Both ends of the hammer should then be covered to prevent the ingress of dirt etc.
It should be laid horizontally in a dry environment ready for use next time.
If this procedure is followed then apart from protecting the hammer from corrosion it will protect the parts
from premature wear and of course reduce ‘down time’ and eventual repair costs.
However we strongly recommend that the hammer, especially if stored for any long period of time,
should be stripped, cleaned, inspected and re-oiled prior to use, to be sure of smooth drilling.
14 TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
REMEDY
INOPERATIVE DRILL
Drill bit blowholes blocked
Dirt inside drill
Worn or damaged parts
Insufficient lubrication
Excessive lubrication
Hanging Piston
Insufficient air pressure
SLOW PENETRATION
Insufficient air pressure
Dull drill bit
Worn drill parts
Too much or too little lubrication
Unblock holes
Strip and clean drill
Replace damaged parts
Check oil level, adjust lube needle value
Adjust lube needle value
Pistion stuck. Polish out the score marks
Check compressor discharge and increase
to operational value
Increase discharge pressure
Re-grind or change bit
Replace worn parts
Check oil level and if necessary adjust lube
needle value
Strip and clean
Drill or increase hole size through the
piston
Clean out blockage
Overhaul drill
Check lubrication
Replace bit
Strip and clean
LOW RETURN AIR VELOCITY
SPASMODIC OPERATION
Dirt in drill
Insufficient hole flushing air passing
through hammer
Drill bit exhaust holes blocked
Failed or damaged parts
Lack of oil
Drill bit broken
Dirt in drill
A. CHUCK RELEASE WASHERS
CHUCK RELEASE WASHERS
HAMMER MODEL
“W”
“D”
HYPER 66DH
0.310” - 7.87mm 0.330” - 8.38mm
Chuck Release Washers are fitted to the Bulroc Range of Hyper Hammers to assist the removal
of the Chuck from the Wearsleeve after drilling.
The Chuck Release Washer is manufactured from a composite material that reduces the friction
between the lock up faces on the Chuck and Wearsleeve making it easier to overcome the
tensional loading applied to these parts during the drilling process.
Due to the forces applied to the Chuck Release Washer you may find that its thickness ("W")
is reduced during the drilling cycle and it is therefore recommended that a new Washer be
fitted each time the Chuck is removed.
It is possible that on some of the larger Hammers in the Bulroc range, when drilling with large
diameter Button Bits or Overburden Systems, certain conditions can generate higher torques
than normally expected, resulting in difficulties when trying to remove the Chuck from the Wearsleeve.
Should this occur then the removal of the Chuck can be achieved by cutting away the Chuck
Release Washer. We do however stress at this point that cutting away the Chuck Release
Washer is a final option and should not be done until all other options have proved unsuccessful.
If the cutting away of the Chuck Release Washer is necessary for the removal of the Chuck then
it must be done with extreme care to avoid damage to either the Chuck or the Wearsleeve.
The composition of the Chuck Release Washer allows for it to be cut with either a hacksaw or
a small hand grinder equipped with a slitting wheel. The hacksaw method is much safer and
less likely to damage the Chuck or Wearsleeve, but obviously much slower than the hand grinder
with a slitting wheel. To remove the Chuck Release Washer a cut must be made in the centre
of the washer all the way around it's circumference, and completely through the Washer,
thus transforming the single washer into two thinner washers that will then spin freely. Great
care must be taken, especially if the Washer is cut with a slitting wheel, to ensure that the cut
only penetrates the Washer and does not pass through into the body of the Chuck.
The size shown as 'D" in the above table should be your MAXIMUM depth of cut, and it is
recommended that either the saw blade or the slitting wheel are marked in some way so as to
indicate when they have achieved this depth.
B. CLAMP POSITIONS
x
CLAMPING POSITION
CLAMP POSITIONS
HAMMER MODEL
HYPER 66DH
CLAMPING POSITION
“X” DISTANCE FROM
WEARSLEEVE END FACE
9.000” / 229mm
Always clamp away from
threads to avoid damage
x
There are many different “Splitting” Machines available for unscrewing the threaded connections on a Bulroc
Hyper Hammer, some are attachments to the Drill Rig, others are independent hydraulic units, or purpose made Bench
arrangements. Regardless of which machine is chosen they all require some method of securing the Wearsleeve whilst
applying a torque to either the Chuck or Backhead.
The most common machines use either Clamps or Chains around the O/D of the Wearsleeve and the positioning of these
is very important, if they are placed too close to the joint being “Split” they will in effect increase the frictional forces on the
threaded connection making it impossible to unscrew the component from the Wearsleeve.
The above table shows the correct position for the clamping mechanism to ensure no additional load will be applied to the
threaded connection, thus making the joint easier to split.
Due to the high torque loads applied to a Hammer during its drilling cycle, equally high loads are required to “Split” the
Chuck and Backhead away from the Wearsleeve and because of this the clamping arrangement around the Wearsleeve
must generate enough friction to prevent it from spinning during the process. However, great care must be taken to make
sure the clamps or chains are not over-tightened as this can cause deformation to the Wearsleeve that can result in both
Wearsleeve failure and Piston seizure once the Hammer is returned to service.
To help increase the Wearsleeve’s resistance to deformation it is recommended that the Hammer Piston is first slid to the
end of the Hammer being “split”, before clamps of chains are attached. By doing this the Piston O/D will limit the amount of
deformation in the Wearsleeve bore if too much clamping pressure is applied.
NOTE:
The use of Chain type Hydraulic Breakers can leave deep intrusions in the O/D of the Wearsleeve which may result in stress
concentrations that could lead to premature failure of the Wearsleeve.
Your Bulroc Hyper 66DH Hammer has been proudly
manufactured in Great Britain
Manufacturers of Rock Drilling Equipment
Turnoaks Business Park, Burley Close, Chesterfield ,Derbyshire S40 2UB
Tel: +44(0) 1246 544700 Fax: +44(0) 1246 544701
E-mail: [email protected] website bulroc.com
HYPER 66DH360 16/10/13